Fire-resistant roof system and membrane composite

Patent metadata

Field	Value
Publication number	US-9523203-B2
Application number	US-201414162273-A
Country	US
Kind code	B2
Filing date	Jan 23, 2014
Priority date	Jan 23, 2013
Publication date	Dec 20, 2016
Grant date	Dec 20, 2016

Abstract

A roof assembly comprising: a roof deck; a thermoplastic membrane covering the deck; and a fabric having disposed thereon expandable graphite.

First claim

What is claimed is:

1. A roof assembly comprising:
(a) a roof deck; and
(b) a composite covering the roof deck, where the composite includes a thermoplastic membrane having first and second planar surfaces and a fabric backing attached to at least a portion of the second planar surface of the membrane, where the fabric backing includes first and second planar surfaces, where the first planar surface of the fabric is attached to the membrane, where the second planar surface of the fabric has a coating composition disposed thereon, where the coating composition includes expandable graphite dispersed within a binder, where the amount of coating composition disposed on the second planar surface of the fabric is substantially greater than any amount of coating disposed on the first planar surface of the fabric, and where the second planar surface of the fabric is proximate to said roof deck relative to the second planar surface of the fabric.

2. The roof assembly of claim 1 , where the deck is combustible.

3. The roof assembly of any of claim 1 , where combustible deck is wood.

4. The roof assembly of claim 1 , where the thermoplastic membrane includes a thermoplastic polyolefin sheet.

5. The roof assembly of claim 1 , where the fabric includes a polyester fleece.

6. The roof assembly of any claim 1 , where the fleece is secured to the thermoplastic membrane by being at least partially embedded into the planar surface of the thermoplastic membrane.

7. The roof assembly of claim 1 , where the assembly is applied directly to the combustible deck.

8. The roof assembly of claim 1 , where the roof assembly further includes a layer of insulation.

9. The roof assembly of claim 1 , where the assembly is applied directly over the layer of insulation.

10. The roof assembly of claim 1 , where the roof assembly achieves a Class A rating pursuant to UL 790and/or ASTM E 108.

11. The membrane of claim 10 , where the fabric is in the form of a backing attached to the membrane.

12. The membrane of claim 10 , where the fabric is a fleece.

13. The membrane of claim 10 , where the fabric is a glass mat.

14. The roof assembly of claim 1 , where the roof assembly includes a single fabric.

15. The membrane of claim 1 , where the thermoplastic membrane includes opposing first and second planar surfaces, and where the fabric is secured to at least a portion of said first planar surface.

16. The membrane of claim 15 , where said fabric is heat laminated to said planar surface.

17. The membrane of claim 16 , where said thermoplastic membrane is a polyolefin sheet.

18. The membrane of claim 1 , where a lap edge of said planar surface of said thermoplastic membrane having the fabric secured thereto remains exposed to thereby provide weldable surface without said fabric.

19. The membrane of claim 1 , where the amount of coating composition disposed on the second planar surface of the fabric is substantially greater than any amount of coating disposed on the first planar surface of the fabric by virtue of the coating composition being applied to only the second planar surface of the fabric.

20. The membrane of claim 1 , where said fabric backing is attached to at least a portion of the second planar surface of the membrane by heat lamination.

21. A membrane composite comprising:
(i) a thermoplastic membrane having first and second planar surfaces; and
(ii) a fabric secured to at least a portion of the second planar surface of the membrane, where the fabric includes first and second planar surfaces, where the first planar surface of the fabric is attached to the second planar surface of the membrane, where the second planar surface of the fabric has a coating composition disposed thereon, where the coating composition includes expandable graphite dispersed within a binder, where the amount of coating composition disposed on the second planar surface of the fabric is substantially greater than any amount of coating disposed on the first planar surface of the fabric.

22. The membrane of claim 21 , where the thermoplastic membrane includes first and second thermoplastic layers laminated to each other.

23. The membrane of claim 22 , where the thermoplastic membrane includes a reinforcing fabric sandwiched between said first and second thermoplastic layers.

24. The membrane of claim 23 , where said first and second thermoplastic layers have a thickness from about 15 to about 70 mils.

25. The membrane of claim 24 , where said first and second thermoplastic layers have a thickness from about 20 to about 60 mils.

26. The membrane of claim 21 , where the thermoplastic membrane includes opposing first and second planar surfaces, and where the fabric is secured to at least a portion of said first planar surface.

27. The membrane of claim 26 , where said fabric is heat laminated to said planar surface.

28. The membrane of claim 26 , where said fabric is adhesively secured to said planar surface.

29. The membrane of claim 21 , where a lap edge of said planar surface of said thermoplastic membrane having the fabric secured thereto remains exposed to thereby provide weldable surface without said fabric.

30. The membrane of claim 21 , where the first planar surface of the fabric is substantially free of the coating composition by virtue of the coating composition being applied to only the second planar surface of the fabric.

Assignees

• Firestone Building Prod Co Llc

Inventors

• Zhou Wensheng
• Hubbard Michael J
• Sopko Allen
• Carr Joseph

Classifications

• D06N5/00

  Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch (compositions of bituminous materials C08L95/00, roof covering E04D5/00, roofing underlays E04D12/002) · CPC title

• E04D5/06

  by making use of plastics · CPC title

• E04D5/10 Primary

  by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen · CPC title

• E04D11/02 Primary

  Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition (gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17) · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title